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3.3 Process variables

Process variable

Explanation

Usage

DCEN

Narrow bead,

deep penetration

Nozzle

Ions

Electrons

When direct-current electrode-negative (straight polarity)

is used:
• Electrons strike the part being welded at a high speed

• Intense heat on the base metal is produced

• The base metal melts very quickly

• Ions from the inert gas are directed towards the

negative electrode at a relatively slow rate

• Direct current with straight polarity does not require

post-weld cleaning to remove metal oxides

For a given diameter of tungsten electrode, higher

amperage can be used with straight polarity. Straight

polarity is used mainly for welding:
• Carbon steels

• Stainless steels

• Copper alloys

The increased amperage provides:
• Deeper penetration

• Increased welding speed

• A narrower, deeper, weld bead

DCEP

Wide bead,

shallow penetration

Nozzle

Ions

Electrons

The DCEP (reverse polarity) are different from the DCEN in

following ways:
• High heat is produced on the electrode rather on the

base metal

• The heat melts the tungsten electrode tip

• The base metal remains relatively cool compared to sing

straight polarity

• Relatively shallow penetration is obtained

• An electrode whose diameter is too large will reduce

visibility and increase arc instability

• Intense heat means a larger diameter of electrode must

be used with DCEP

• Maximum welding amperage should be relatively low

(approximately six times lower than with DCEN)

BOC Smootharc 180 Multiprocess operating manual

Summary of Contents for 180 Multiprocess

Page 1: ...180 Multiprocess Operating manual 6PRRWKDUF GYDQF GYDQF ...

Page 2: ...r correcting any error or omission which may become apparent after the document has been issued Neither BOC nor any of its agents has independently verified the accuracy of the information contained in this document The information in this document is commercial in confidence and is not to be reproduced The recipient acknowledges and agrees that it must make its own independent investigation and s...

Page 3: ...ine 25 4 3 Welding Technique 26 4 4 Electrode Selection 26 4 5 Types of Joints 28 4 6 Fillet Welds 30 4 7 Typical Defects Due to Faulty Technique 32 5 0 General Welding Information 34 5 1 Recommended Welding Parameters for MIG MAG 34 6 0 Correct Application Techniques 35 7 0 Package Contents 37 8 0 Installation 38 8 1 Installation for MIG MAG process 38 8 2 Installation for MIG MAG set up with OPT...

Page 4: ... primary terminals and live parts effectively covered Never strike an arc on any gas cylinder Never use oxygen for venting containers Diagram and safety explanation Electrical safety alert Welding electrode causing electric shock Fumes and gases coming from welding process Welding arc rays Read instruction manual Become trained Wear dry insulated gloves Insulate yourself from work and ground Disco...

Page 5: ... have enough ventilation in confined spaces Be alert to this at all times Keep your head out of the fumes rising from the arc Fumes from the welding of some metals could have an adverse effect on your health Don t breathe them in If you are welding on material such as stainless steel nickel nickel alloys or galvanised steel further precautions are necessary Wear a respirator when natural or forced...

Page 6: ...ed in transit Before operating a cylinder valve Ensure that the system you are connecting the cylinder into is suitable for the gas and pressure involved Ensure that any accessories such as hoses attached to the cylinder valve or the system being connected to are securely connected A hose for example can potentially flail around dangerously if it is accidentally pressurised when not restrained at ...

Page 7: ...sonnel approved by BOC should perform repairs Always disconnect mains power before investigating equipment malfunctions Parts that are broken damaged missing or worn should be replaced immediately Equipment should be cleaned periodically BOC stock a huge range of personal protective equipment This combined with BOC s extensive Gas and Gear network ensures fast reliable service throughout the South...

Page 8: ...ire electrode The shielding gas or gas mixture may consist of the following Argon MIG Carbon dioxide MAG Argon and carbon dioxide mixtures MAG Argon with oxygen mixtures MAG Argon with helium mixtures MIG Each gas or gas mixture has specific advantages and limitations Other forms of MIG MAG welding include using a flux cored continuous electrode and carbon dioxide shielding gas or using self shiel...

Page 9: ... electrical resistance within the flux cored wire is higher than with solid MIG MAG wires and it is this higher electrical resistance that gives this type of wire some of its novel operating properties One often quoted property of fluxed cored wires are their higher deposition rates than solid MIG MAG wires What is often not explained is how they deliver these higher values and whether these can b...

Page 10: ...er an extension nozzle is often used to support and direct the long electrode extensions that are needed to obtain high deposition rates 2 3 Introduction to Metal Cored Arc Welding MCAW How it Works Metal cored arc welding MCAW uses the heat generated by a DC electric arc to fuse metal in the joint area the arc being struck between a continuously fed consumable filler wire and the workpiece meltin...

Page 11: ... to those obtained in MIG MAG welding but here the mode of transfer is heavily dependent on the composition of the flux fill as well as on current and voltage The most common modes of transfer in FCAW are Dip transfer Globular transfer Spray transfer Pulsed arc transfer operation has been applied to flux cored wires but as yet is not widely used because the other transfer modes are giving users wh...

Page 12: ... normally be used for positional welding The main exception is aluminium and its alloys where primarily because of its low density and high thermal conductivity spray transfer in position can be carried out The current flows continuously because of the high voltage maintaining a long arc and short circuiting cannot take place It occurs best with argon based gases In solid wire MIG MAG as the curre...

Page 13: ...polarity on the power source 4 Selection of the correct shielding gas 5 Selection of the correct application techniques a Correct angle of electrode to work b Correct electrical stickout c Correct travel speed 6 Selection of the welding preparation Selection of Correct Consumable Chemical composition As a general rule the selection of a wire is straightforward in that it is only a matter of select...

Page 14: ...rect Polarity on the Power Source Many power sources are fitted with an optional reverse polarity dinse connector To achieve the optimum welding it is important to adhere to the consumable manufacturer s instruction to select the polarity As a general rule all solid and metal cored wires are welded on electrode positive Work return lead fitted to the negative connector Some grades of self shielded...

Page 15: ...for compensation by office workers On all machines a special function called 2T and 4T is available Also referred to as trigger latching this special feature allows the operator to relax the trigger after first depressing it the gas shielding to start before the welding commences This feature is of particular importance as it ensures that the weld will have adequate gas shielding to eliminate the ...

Page 16: ...alternating current power sources with constant current output characteristics are normally employed to supply the welding current For DC operation the tungsten may be connected to either output terminal but is most often connected to the negative pole The output characteristics of the power source can have an effect on the quality of the welds produced Shielding gas is directed into the arc area ...

Page 17: ...ly for welding Carbon steels Stainless steels Copper alloys The increased amperage provides Deeper penetration Increased welding speed A narrower deeper weld bead DCEP Wide bead shallow penetration Nozzle Ions Electrons The DCEP reverse polarity are different from the DCEN in following ways High heat is produced on the electrode rather on the base metal The heat melts the tungsten electrode tip Th...

Page 18: ...agnesium alloys Argon Used with continuous high frequency AC Good arc stability Good cleaning action Stainless steel Argon Good penetration Good arc stability Helium Deeper penetration Titanium Argon Stable arc Helium High speed welding 3 5 Welding wire selection The following table includes the recommended welding consumable for the most commonly welded materials Base material BOC Consumable C Mn...

Page 19: ...starts Good stability Mild Steels Carbon Steels Alloy Steels Stainless Steels and Titanium alloys All General purpose DCSP 2 Thoriated EW Th2 75 Argon 25 Helium Best stability at medium currents Good arc starts Medium tendency to spit Medium erosion rate 2 Ceriated EW Ce2 75 Argon 25 Helium Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability 2 Lanthanated ...

Page 20: ...ed ceriated and lanthanated tungsten electrodes do not ball as readily as pure or zirconiated tungsten electrodes and as such are typically used for DCSP welding These electrodes maintain a ground tip shape much better than the pure tungsten electrodes If used on AC thoriated and lanthanated electrodes often spit Regardless of the electrode tip geometry selected it is important that a consistent t...

Page 21: ...ace This is the same as holding the torch 15 30 from the vertical Take special note that the rod is in the shielding gas during the welding process 3 8 Torch movement during welding Tungsten Without Filler Rod Tungsten With Filler Rod 75 75 15 Welding direction Form pool Welding direction Form pool 75 75 15 Tilt torch 75 75 15 Tilt torch 75 75 15 Move torch to front of pool Repeat 75 75 15 Add fil...

Page 22: ...5 75 Corner Joint 15 75 90 20 40 30 15 75 90 20 70 20 10 15 75 15 75 90 20 40 15 75 90 20 70 20 10 15 75 90 20 40 30 90 20 10 Lap Joint 90 20 40 30 20 10 15 75 90 20 40 30 15 75 90 20 70 20 10 15 75 15 75 90 20 40 30 15 75 90 20 70 20 10 15 75 3 9 Positioning torch tungsten for various weld joints 22 BOC Smootharc 180 Multiprocess operating manual ...

Page 23: ... 40 1 5 3 50 50 15 40 20 6 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 r s 2 s 2 3 0 S 2 3...

Page 24: ...angle Loss of gas coverage Angular mis alignment Unsymmetrical bead profile Mis alignment Incomplete penetration Filler rod removed from gas shield Tungsten inclusions Tungsten inclusions Electrode contact with the weld pool Rod movement Oxides Air 24 BOC Smootharc 180 Multiprocess operating manual ...

Page 25: ... the number of cycles completed per second The standard frequency of the AC supply in Australia is 50 Hz Hertz 4 2 Welding Machine The most important consideration when contemplating the use of arc welding for the first time is the purchase of a suitable welding machine BOC supplies a popular range of arc welding machines Machines range from small portable welders that operate from standard 240 Vo...

Page 26: ...ttractive electrode of its class Continuous development and improvement of BOC Smootharc 13 has provided in built operating qualities which appeals to the beginner and experienced operator alike For further recommendations on the selection of electrodes for specific applications see table page 27 Electrodes and Typical Applications Name AWS Class Application BOC Smootharc 13 E6013 A premium qualit...

Page 27: ...eing used When using machines with adjustable current set on the current range specified The limits of this range should not normally be exceeded The following table shows the current ranges generally recommended for BOC Smootharc 13 Generally Recommended Current Range for BOC Smootharc 13 Size of Electrode mm Current Range Amp 2 5 60 95 3 2 110 130 4 0 140 165 5 0 170 260 Arc Length To start the ...

Page 28: ...ribes the various joint types and areas of application 4 5 Types of Joints Butt Welds A butt weld is a weld made between two plates so as to give continuity of section Close attention must be paid to detail in a butt weld to ensure that the maximum strength of the weld is developed Failure to properly prepare the edges may lead to the production of faulty welds as correct manipulation of the elect...

Page 29: ... butt weld should be deposited with an electrode not larger than 4 0 mm The angle of the electrode for the various runs in a butt weld is shown It is necessary to maintain the root gap by tacking at intervals or by other means as it will tend to close during welding All single V single U and square butt welds should have a backing run deposited on the underside of the joint otherwise 50 may be ded...

Page 30: ...he joints of tanks or other fabrications where corrosion is likely to occur behind the lapped plates In applying fillet welds to lapped joints it is important that the amount of overlap of the plates be not less than five times the thickness of the thinner part Where it is required to preserve the outside face or contour of a structure one plate may be joggled Corner Joints The members are fitted ...

Page 31: ...oat Thickness mm Plate Thickness mm Electrode Size mm 5 0 3 5 5 0 6 3 3 2 6 3 4 5 6 3 12 4 0 8 0 5 5 8 0 12 over 4 0 10 0 7 0 10 over 4 0 Selection of welding current is important If it is too high the weld surface will be flattened and undercut accompanied by excessive spatter is likely to occur Alternatively a current which is too low will produce a rounded narrow bead with poor penetration at t...

Page 32: ...results High current will cause undercutting and bad shape of the weld while low current will cause slag inclusions To produce a weld having good penetration and of good profile a short arc length is necessary Angle of electrode for overhead fillets is illustrated above 4 7 Typical Defects Due to Faulty Technique Manual metal arc welding like other welding processes has welding procedure problems ...

Page 33: ...ented by choosing the proper welding current for the type and size of electrode and the welding position holding the arc as short as possible pausing at each side of the weld bead when a weaving technique is used using a travel speed slow enough so that the weld metal can completely fill all of the melted out areas of the base metal Lack of Fusion LACK OF FUSION Lack of fusion is when the weld met...

Page 34: ...0 80 150 160 180 Voltage volts 14 16 16 17 16 18 16 18 23 25 Wire feed speed m min 3 5 5 0 4 0 7 0 4 0 7 0 4 0 7 0 7 5 9 0 Gas rate flow L min 15 15 15 15 15 Travel speed mm min 350 500 350 500 320 500 280 450 800 1000 Stainshield Aus or Stainshield Light NZ Indicative Welding Parameters Dip Transfer Material thickness mm 4 6 8 Welding position Horizontal Vertical Horizontal Vertical Horizontal Ve...

Page 35: ...rcement 10 Torch positioned at a drag angle of 10 narrow bead with excessive reinforcement Flux cored welding with cored wires takes place normally with the drag technique The welding torch is tilted at an angle of 10 away from the direction of welding For all other applications the torch angle remains the same 90 90 0 15 Torch position for butt welds When welding butt welds the torch should be po...

Page 36: ...an increase in the electrical resistance The resultant increase in temperature has a positive influence in the melt off rate of the wire that will have an influence on the weldbead profile Influence of the change in electrical stickout length on the weldbead profile The travel speed will have an influence on the weldbead profile and the reinforcement height If the travel speed is too slow a wide w...

Page 37: ...26 torch Binzel MB15AK MIG MAG torch Regulator Gas hose Spare feed rolls Operating manual Optional Spool gun not part of this package Purchased separately 37 BOC Smootharc 180 Multiprocess operating manual 10 Euro output connection 11 Positive terminal 12 Short mechanical connector 14 Negative terminal 13 Control connector ...

Page 38: ...nk plug into the 14 negative terminal and the B work return lead into the 11 positive terminal 8 2 Installation for MIG MAG set up with OPTIONAL spool gun 1 Connect the gas cylinder to the regulator Select correct shielding gas for the application 2 Plug S1 spool gun euro connection into 10 euro output connection 3 Plug S2 spool gun control cable into 13 control connection 4 Fit wire spool to the ...

Page 39: ...k return lead to 11 positive terminal on the front panel and fasten it clockwise Connect the clamp end to the work piece 4 The 12 short mechanical connector link plug should remain hanging free 8 4 Installation for MMA process 1 Connect the A electrode holder to the 11 positive terminal of the machine and fasten it clockwise 2 Connect the B work return lead into the 14 negative terminal of the mac...

Page 40: ...G MAG mode This is important for certain types of self shielded flux cored wires This can be achieved by switching the B work return lead to the 11 positive terminal and the 12 short mechanical connector link plug to the 14 negative terminal for a DC electrode negative polarity setting 9 0 Control panels 4 Spool gun indicator 3 Multifunctional data adjustment 6 Lift TIG indicator 7 MIG indicator 8...

Page 41: ...ding the torch switch without welding To stop wire feeding press the torch switch again 2 2T 4T mode Under MIG mode press 2 Data Selection Key for 2 Seconds to choose the 2T 4T mode The welding mode 2T 4T can be selected by depressing the 2 Data Selection Key The selected mode will be shown on the 1 Multifunctional Data Display Refer to the section on MIG Fundaments in this manual for an explanati...

Page 42: ...MIG Pulse Al Aluminum 1 0 mm Recommend 2 8 m min When welding aluminum please fit the dedicated wire feeding rolls and replace the torch liner and contact tips with wear parts suitable for aluminum Operation instruction under MIG mode using spool gun 1 The machine will go in to the spool gun welding mode when connecting with the spool gun The 4 spool gun indicator and 7 MIG indicator lights up Ill...

Page 43: ...ill revert to the preset welding current after 5 seconds when welding has stopped 10 4 Operation instruction under MMA mode 1 Set welding mode Press the 9 Function Switch Key to MMA mode 5 MMA indicator light will illuminate 2 VRD function Press the 2 Data Selection Key for 3 seconds The VRD reduces open circuit voltage to a safe limit Illustration 11 shows MMA mode using VRD Press the 2 Data Sele...

Page 44: ...parameters before malfunction occurred 2 Error display of over current The panel displays as Illustration 14 when over current occurs The 1 Multifunctional Data Display flashes continuously when the machine is not working Restart the machine The panel will display the previous parameters before malfunction occurred 3 Error display of overheating protection The panel displays as Illustration 15 whe...

Page 45: ...45 BOC Smootharc 180 Multiprocess operating manual ...

Page 46: ...ow directions as set out on page 43 Poor scratch starting technique Many codes do not allow scratch starts Use copper strike plate Use high frequency arc starter Excessive current for tungsten size used Reduce the current or use larger electrode Accidental contact of electrode with puddle Maintain proper arc length Accidental contact of electrode to filler rod Maintain a distance between electrode...

Page 47: ...out Use a larger size cup Excessive turbulence in gas stream Change to gas safer parts or gas lens parts Short parts Life Cause Solution Cup shattering or cracking in use Change cup size or type Change tungsten position Short collet life Ordinary style is split and twists or jams Change to wedge style Short torch head life Do not operate beyond rated capacity Do not bend rigid torches The phenomen...

Page 48: ...t Fault symptom Cause Type Welding torch overheats Welding torch underrated for welding application Liners Erratic wire feed wire snarls up at outlet guide Liner of incorrect type and size for wire in use worn or dirty liner liner too long or too short Gas distributor Inadequate gas flow contaminated or porous weld Damaged or blocked distributor Nozzle Inadequate gas cover restricted joint accessi...

Page 49: ...speed with rapid freezing of weld trapping gases before they escape Lower travel speed Contaminated shield gas Replace the shielding gas Inadequate shielding Cause Solution Gas flow blockage or leak in hoses or torch Locate and eliminate the blockage or leak Excessive travel speed exposes molten weld to atmospheric contamination Use slower travel speed or carefully increase the flow rate to a safe...

Page 50: ... planning maintenance frequency of your Smootharc welder Preventative maintenance will ensure trouble free welding and increase the life of the machine and its consumables 12 1 Power Source Check electrical connections of unit at least twice a year Clean oxidised connections and tighten Inner parts of machine should be cleaned with a vacuum cleaner and soft brush Do not use any pressure washing de...

Page 51: ...t 32 180A 10 180A 10 160A Duty cycle 20 180A 160A 25 180A Wire feeder Internal or optional spool gun sold separately Internal wire feeder speed 3 to11m min Post flow time 3 Seconds Welding wire diameter 0 8 1 0mm Remote control No Efficiency 80 Power factor 0 73 Insulation grade H Housing shielding grade IP21S EMG grade B Welding thickness 0 8mm Dimensions L W H 420 220 439mm Weight 12 8kg Standar...

Page 52: ... costs Modification of the 15A primary input plug or fitment of a lower rated primary input plug will render the warranty null and void NOTE Under the terms of warranty welding torches and their consumables are not covered Direct or indirect damage due to a defective product is not covered under the warranty The warranty is void if changes are made to the product without approval of the manufactur...

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Page 56: ...e of printing Whilst proper care has been taken in the preparation no liability for injury or damage resulting from its improper use can be accepted For more information contact the BOC Customer Engagement Centre on 131 262 AU or 0800 111 333 NZ BOC Limited ABN 95 000 029 729 10 Julius Avenue North Ryde NSW 2113 Australia www boc com au BOC Limited WN007748 970 988 Great South Road Penrose Aucklan...

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